Motor vehicle pedals and manufacturing methods thereof

ABSTRACT

According to an implementation a method for manufacturing a pedal for a motor vehicle is provided. The method comprising inserting into a hollow profile a flexible yet substantially incompressible retainer member and subsequently applying one or more forces to an external surface of the hollow profile to induce a change in shape of the hollow profile from a first shape to a second shape. The substantial incompressibility of the retainer member inhibiting deformations in the internal wall surface of the hollow profile as the one or more forces are applied to the external wall surface of the hollow profile so that the internal wall surface is substantially free of deformations upon the hollow profile assuming the second shape, the flexibility of the retainer member allowing it to bend in the direction of the applied one or more forces to accommodate a change in shape of the hollow profile from the first shape to the second shape.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application relates to and claims priority to Spanish PatentApplication No. P201131700, filed Oct. 21, 2011.

TECHNICAL FIELD

This invention relates to a method for manufacturing a pedal for a motorvehicle and a pedal obtained according to the manufacturing method.

BACKGROUND

Known motor vehicle pedals have irregular shapes in more than onedirection, their manufacture being complex. For their fabrication, onmany occasions the process starts with a closed contour obtained bydifferent techniques and subsequently subjected to bending, curvingand/or cutting operations.

Spanish Publication No. ES2269332T3 describes a manufacturing method inwhich in order to avoid welding, the process starts with a conical pipe,the final shape of the pedal being obtained by means of a series ofbending and flattening operations on one part of it.

One problem associated with these manufacturing methods is thegeneration of internal deformations inside the hollow pipe or closedhollow profile when they are subjected to forming operations.

SUMMARY OF THE DISCLOSURE

According to some implementations a manufacturing method is providedthat comprises at least one stamping stage. In some implementations thepedal comprises a hollow profile inside which is inserted at least oneretainer member that is flexible and substantially incompressible. Theretainer member is inserted inside the profile of the pedal before thecorresponding stamping stage is performed.

As a result, during the stamping stage internal deformations caused bythe bending of the profile of the pedal towards its interior areinhibited or otherwise prevented from occurring. Said internaldeformations are generated, in particular, on pedals with verypronounced curvatures, defined with small radii, or on pedals havingexcessive width. As well as not being aesthetic, internal deformationsare harmful to the subsequent mechanical behaviour of the pedal and mayeven make the pedal impossible to manufacture.

The retainer member is flexible so that it may adapt to the deformationsof the profile of the pedal in the direction of stamping, allowingstamping to be carried out in a simple manner. In addition, saidretainer member is substantially incompressible, in order to preventdeformations of the profile occurring in other directions, in particulardeformations towards the inside of the profile during said stamping.

These and other advantages and characteristics will be made evident inthe light of the drawings and the detailed description thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an exploded view of the pedal, which comprises a profileand a retainer member, prior to being formed.

FIG. 2 shows a sectional view of the pedal shown in FIG. 1, with theretainer member inserted inside the profile, prior to being formed.

FIG. 3 shows another view in perspective of the retainer member shown inFIG. 1.

FIG. 4 shows a side view of the pedal shown in FIG. 1, after a firstforming stage.

FIG. 5 shows a front view of the pedal shown in FIG. 1, after a secondforming stage.

FIG. 6 shows a view in perspective of the pedal shown in FIG. 1, afterthe pedal has been formed.

FIG. 7 shows a partially sectional view of the pedal shown in FIG. 1,after the pedal has been formed.

FIG. 8 shows a view in perspective of the retainer member shown in FIG.1, after the pedal has been formed.

DETAILED DESCRIPTION

FIGS. 1, 2 and 4 to 6 schematically show a process for manufacturing apedal 1 adapted to a motor vehicle, according to an implementation. Theprocess for manufacturing also applies to structures other than motorvehicle pedals. The pedal 1 obtained according to a manufacturingmethod, described below, comprises a metal hollow profile 3, with asubstantially rectangular cross-profile, and at least one retainermember 2 housed inside the profile 3, said retainer member 2 beingarranged trapped inside the profile 3. According to some implementationsthe stamped profile 3 obtained does not include internal deformations,or is substantially free of internal deformations.

In order to obtain the pedal 1, the process according to someimplementations starts with a hollow profile 3, with a substantiallyprismatic shape, inside which is inserted a retainer member 2, as shownin FIGS. 1 and 2. The retainer member 2 has a shape adapted to theinternal shape of the profile 3, the shape of the substantiallyprismatic profile 3 being defined by side walls 3 b substantiallyparallel to each other and front walls 3 a. As a result, when saidretainer member 2 is inserted inside the profile 3 it is retained insidethe profile 3 by the shape of the profile 3 itself.

In the implementation shown in the figures, the retainer member 2 has asubstantially quadrilateral cross-profile and comprises side walls 2 b,substantially parallel to each other, and front walls 2 a thatlongitudinally connect the side walls 2 b to each other. In theimplementation shown in the figures, the side walls 2 b of the retainermember 2 are arranged to face the side walls 3 b of the hollow profile 3and the front walls 2 a of the retainer member 2 are arranged to facethe front walls 3 a of the hollow profile 3.

In other implementations, not shown in the figures, both the profile 3and the retainer member 2 may have a substantially pyramidal shape orother shapes, in which the respective side walls 3 b, 2 b are notparallel to each other. In other implementations the shape may even beconical.

According to some implementations once the retainer member 2 is housedinside the profile 3, the pedal 1 is subjected to a first stampingstage. In said first stage, the pedal 1 is subjected to at least oneload F1, F1′, F1″ on at least one front wall 3 a of the profile 3, in adirection substantially orthogonal to the front wall 3 a. In theimplementation shown in the figures, the pedal 1 is subjected during thefirst stage to various consecutive stamping operations, in each of whicha load Fl, F1′, F1″ is exerted on the corresponding front wall 3 a ofthe profile 3, said respective load being transmitted to the respectivefront wall 2 a of the retainer member 2, and the pedal 1 adopting thegeometric shape shown in FIG. 4. The loads F1, F1′, F1″ do not have tobe equal, said loads being exerted on different points along thecorresponding front wall 3 a.

According to some implementations, after the first stamping stage, thepedal 1 is subjected to a second stamping stage. In the second stage thepedal 1 is subjected to at least one load F2, F2′, F2″ on at least oneside wall 3 b of the profile 3, in a direction substantially orthogonalto said side wall 3 b. In the embodiment shown in the figures, the pedal1 is subjected during the second stage to various consecutive stampingoperations, in each of which is respectively exerted a load F2, F2′, F2″on a side wall 3 b of the profile 3, said respective load beingtransmitted to the respective side wall 2 b of the retainer member 2,and the pedal 1 adopting the geometric shape shown in FIG. 5. The loadsF2, F2′, F2″ do not have to be equal, said loads being exerted ondifferent points along the side wall 3 b correspondingly.

The retainer member 2, shown in detail in FIGS. 3 and 8, is flexible andsubstantially incompressible. As a result, the retainer member 2 isflexible in the direction of application of the loads F1, F1′, F1″, F2,F2′ and F2″, adapting itself to the respective deformations of the sidewalls 3 b or front walls 3 a of the profile 3, side walls 3 b or frontwalls 3 a, where the corresponding load F1, F1′, F1″, F2, F2′ and F2″ isapplied. At the same time, the retainer member 2 is substantiallyincompressible, the distance between the side walls 3 b and the frontwalls 3 a respectively being substantially maintained. For this purpose,according to some implementations, the retainer member 2 comprises aplurality of cross-profiles 4 arranged along the front walls 2 a,substantially transversal to said front walls 2 a. In the implementationshown in the figures, the profile 4 is a gap that passes substantiallyorthogonally through the side walls 2 b. The gaps 4 are arranged spacedalong the length of the retainer member 2.

As a result, when the loads F1, F1′ and F1″ are applied on therespective front walls 3 a of the profile 3, the gaps 4 allow theretainer member 2 to bend in the direction of application of the loads,allowing the profile 3, in particular the front walls 3 a, to becomedeformed in said direction. Thanks to the incompressibility of saidretainer member 2, deformations in other directions are prevented, inparticular deformations of the front walls 3 a of the profile 3 areprevented, the distance between both front walls 3 a being kept constantor substantially constant.

In addition, when the loads F2, F2′ and F2″ are applied on therespective side walls 3 b of the profile 3, the gaps 4, which also passthrough the side walls 2 b of the retainer member 2, allow said retainermember 2 to bend in the direction of application of the loads, allowingthe profile 3, in particular the side walls 3 b, to become deformed insaid direction. As in the previous stage, thanks to theincompressibility of said retainer member 2, deformations in otherdirections are prevented, in particular deformations of the front walls3 a of the profile 3 are prevented, the distance between both side walls3 b being kept constant or substantially constant.

As a result, a stamped profile of a pedal is obtained and which does notinclude internal deformations or is substantially free of internaldeformations.

In some implementation the retainer member 2 is made of a plasticmaterial, in particular high-density polyethylene. In other embodimentsnot shown in the figures, the material may be polypropylene,polystyrene, polyethylene, polyamide or even an elastomer that isflexible and substantially incompressible, while other materials thatfulfil both requirements may also be used.

In some implementations the retainer member 2 also comprises holes 10that are arranged longitudinally spaced out, said holes 10 passingthrough the side walls 2 b of the retainer member 2. The holes 10lighten the weight of the retainer member 2 as well as making saidretainer member 2 flexible. In the implementation shown, some holes 10are connected to the corresponding gaps 4, thereby increasing theflexibility of the retainer member 2 in the area.

In other implementations not shown in the figures, the retainer member 2may not comprise the gaps 4 and the holes 10, as long as the materialused is sufficiently flexible, substantially incompressible, and is nottoo heavy.

FIGS. 6 and 7 show a motor vehicle pedal 1 manufactured by means of amanufacturing method according to one implementation. In theimplementation shown in the figures, the pedal 1 comprises a singleretainer member 2, while in other implementations not shown in thefigures the pedal 1 may comprise a plurality of retainer members 2arranged adjacent to each other inside the profile 3.

The present description does not include specific details of the bendingor stamping stages or the machines and tools on which said stages areperformed, as they are known in the art and are not considered necessaryfor the correct understanding of the implementations disclosed andcontemplated herein.

In addition, in the implementation shown in the figures the profile 3comprises holes 11 for the passage of an axis of rotation of the pedal1, not shown in the figures. In other embodiments, said holes may beformed in the profile 3 at a later stage.

The pedal 1 may be a brake pedal, accelerator or even a clutch.

1.-26. (canceled)
 27. A structure having a first shape that is capableof assuming a second shape upon one or more forces being applied to anexternal wall surface thereof, the structure comprising: a metallicrigid member having a hollow interior with an internal wall surface, themetallic rigid member having an external wall surface that is theexternal wall surface of the structure; and a flexible yet substantiallyincompressible retainer member disposed within the hollow interior ofthe metallic rigid member, the retainer member having an external wallsurface that is adapted to the internal wall surface of the metallicrigid member, the flexibility of the retainer member allowing it to bendin the direction of the one or more applied forces to accommodate achange in shape of the structure from the first shape to the secondshape, the substantial incompressibility of the retainer memberinhibiting deformations in the internal wall surface of the metallicrigid member upon the one or more forces being applied to the externalwall surface of the structure.
 28. A structure according to claim 27,wherein the metallic rigid member comprises first and second side wallsand first and second front walls, an interior surface of each of thefirst side wall, second side wall, first front wall and second frontwall of the metallic rigid member collectively forming the internal wallsurface of the metallic rigid member; the retainer member comprisingfirst and second side walls and first and second front walls, anexterior surface of each of the first side wall, second side wall, firstfront wall and second front wall of the retainer member collectivelyforming the external wall surface of the retainer member, the exteriorsurface of each of the first and second front walls of the retainermember comprising a plurality of spaced-apart gaps along a lengththereof.
 29. A structure according to claim 28, wherein the retainermember comprises a plurality of spaced-apart holes that extend throughthe first and second side walls of the retainer member.
 30. A structureaccording to claim 28, wherein the retainer member comprises a pluralityof spaced-apart holes that extend partially into one or both of thefirst and second side walls of the retainer member.
 31. A structureaccording to claim 29, wherein at least some of the plurality of gapsextend into at least some of the plurality of spaced-apart aperturesthat extend through the first and second side walls of the retainermember.
 32. A structure according to claim 30, wherein at least some ofthe plurality of gaps extend into at least some of the plurality ofspaced-apart apertures that extend partially through the first andsecond side walls of the retainer member.
 33. A structure according toclaim 27, wherein the retainer member is made of a plastic material. 34.A structure according to claim 33, wherein the plastic material isselected from the group consisting of: polypropylene, polystyrene,polyethylene and polyamide.
 35. A structure according to claim 33,wherein the plastic material comprises high-density polyethylene.
 36. Astructure according to claim 27, wherein the retainer member is madefrom an elastomer that is flexible and substantially incompressible. 37.A structure having a first shape and that is capable of assuming asecond shape upon one or more forces being applied to an external wallsurface thereof, the structure comprising: a metallic rigid memberhaving a hollow interior with an internal wall surface, the metallicrigid member comprising first and second side walls separated by a firstdistance and first and second front walls separated by a seconddistance, an interior surface of each of the first side wall, secondside wall, first front wall and second front wall collectively formingthe internal wall surface of the metallic rigid member, the metallicrigid member having an external surface that is the external surface ofthe structure; and a flexible yet substantially incompressible retainermember disposed within the hollow interior of the metallic rigid member,the retainer member having an external wall surface that is adapted tothe internal wall surface of the metallic rigid member, the flexibilityof the retainer member allowing it to bend in the direction of theapplied one or more forces to accommodate a change in shape of thestructure from the first shape to the second shape, the substantialincompressibility of the retainer member keeping the first distance andthe second distance substantially constant upon the one or more forcesbeing applied to the external wall surface of the structure.
 38. Astructure according to claim 37, wherein the retainer member comprisesfirst and second side walls and first and second front walls, anexterior surface of each of the first side wall, second side wall, firstfront wall and second front wall of the retainer member collectivelyforming the external wall surface of the retainer member, the exteriorsurface of each of the first and second front walls of the retainermember comprising a plurality of spaced-apart gaps along a lengththereof.
 39. A structure according to claim 38, wherein the retainermember comprises a plurality of spaced-apart holes that extend throughthe first and second side walls of the retainer member.
 40. A structureaccording to claim 38, wherein the retainer member comprises a pluralityof spaced-apart holes that extend partially into one or both of thefirst and second side walls of the retainer member.
 41. A structureaccording to claim 39, wherein at least some of the plurality of gapsextend into at least some of the plurality of spaced-apart aperturesthat extend through the first and second side walls of the retainermember.
 42. A structure according to claim 40, wherein at least some ofthe plurality of gaps extend into at least some of the plurality ofspaced-apart apertures that extend partially through the first andsecond side walls of the retainer member.
 43. A structure according toclaim 37, wherein the retainer member is made of a plastic material. 44.A structure according to claim 43, wherein the plastic material isselected from the group consisting of: polypropylene, polystyrene,polyethylene and polyamide.
 45. A structure according to claim 43,wherein the plastic material comprises high-density polyethylene.
 46. Astructure according to claim 37, wherein the retainer member is madefrom an elastomer that is flexible and substantially incompressible.